U.S. patent application number 11/364217 was filed with the patent office on 2006-09-21 for vehicle body attachment part, intermediate product and method of producing such vehicle body attachment part.
Invention is credited to Harald Batke, Herbert Beck, Sven Hardel, Hans-Joachim Langhoff, Matthias Ludwig, Frank Niebuhr, Tobias Niesner.
Application Number | 20060208539 11/364217 |
Document ID | / |
Family ID | 35406247 |
Filed Date | 2006-09-21 |
United States Patent
Application |
20060208539 |
Kind Code |
A1 |
Ludwig; Matthias ; et
al. |
September 21, 2006 |
Vehicle body attachment part, intermediate product and method of
producing such vehicle body attachment part
Abstract
A vehicle body attachment part for a motor vehicle, in
particular a roof module, comprises a large-area outer skin having
first and second large-area outer skin portions that are formed
from different materials. The vehicle body attachment part also
includes a rear carrier layer that receives the outer skin. The
first large-area outer skin portion is formed by a foil and the
rear carrier layer is formed by providing the foil with a foamed
backing. The carrier layer integrally extends under the second
large-area outer skin portion, which is subsequently fastened to
the rear carrier layer.
Inventors: |
Ludwig; Matthias; (Vechelde,
DE) ; Niebuhr; Frank; (Wilsche, DE) ; Batke;
Harald; (Mueden/Aller, DE) ; Langhoff;
Hans-Joachim; (Gifhorn, DE) ; Niesner; Tobias;
(Gifhorn, DE) ; Hardel; Sven; (Wettendorf, DE)
; Beck; Herbert; (Wolfenbuttel, DE) |
Correspondence
Address: |
CARLSON, GASKEY & OLDS, P.C.
400 WEST MAPLE ROAD
SUITE 350
BIRMINGHAM
MI
48009
US
|
Family ID: |
35406247 |
Appl. No.: |
11/364217 |
Filed: |
February 28, 2006 |
Current U.S.
Class: |
296/210 |
Current CPC
Class: |
B62D 29/04 20130101;
B62D 65/06 20130101; B62D 25/06 20130101 |
Class at
Publication: |
296/210 |
International
Class: |
B62D 25/06 20060101
B62D025/06 |
Foreign Application Data
Date |
Code |
Application Number |
Mar 18, 2005 |
EP |
05 005 971.6 |
Claims
1. A vehicle body attachment part for a motor vehicle comprising: a
large-area outer skin having first and second large-area outer skin
portions that are formed from different materials; and a rear
carrier layer carrying the large-area outer skin, the first
large-area outer skin portion being formed by a foil and the rear
carrier layer being formed with a foamed backing on the foil,
wherein the rear carrier layer integrally extends under the second
large-area outer skin portion that is subsequently attached to the
rear carrier layer.
2. The vehicle body attachment part according to claim 1 wherein
the rear carrier layer has a large-area opening in a region of the
second large-area outer skin portion and extends around the
large-area opening as a frame.
3. The vehicle body attachment part according to claim 2 wherein
the frame extends in one piece and in a circumferentially closed
manner around the large-area opening.
4. The vehicle body attachment part according claim 1 wherein the
second large-area outer skin portion is made of one of a
transparent and translucent material.
5. The vehicle body attachment part according to claim 4 wherein
the second large-area outer skin portion is made of glass.
6. The vehicle body attachment part according to claim 1 wherein
the second large-area outer skin portion is bonded to the rear
carrier layer.
7. The vehicle body attachment part according to claim 1 including
a third outer skin portion that is arranged on the rear carrier
layer and constituted by a part that is separate with respect to
the first and second large-area outer skin portions.
8. The vehicle body attachment part according to claim 7 wherein
the third outer skin portion is one of: a foil; a part made of one
of a transparent and translucent material; and a solar panel.
9. The vehicle body attachment part according to claim 1 wherein
the foil extends under an edge of the second large-area outer skin
portion that faces the foil.
10. The vehicle body attachment part according to claim 9 wherein a
portion of the foil that extends under the edge is configured as a
water drain groove.
11. The vehicle body attachment part according to claim 7 including
a projection formed on the rear carrier layer that serves as a
spacer with one of the second large-area outer skin portion and
third outer skin portion resting on the projection in a region
without being fastened to the projection in the region.
12. The vehicle body attachment part according to claim 1 wherein
the vehicle body attachment part comprises a roof module.
13. An intermediate product for manufacturing a vehicle body
attachment part for a motor vehicle comprising: a continuous
one-piece carrier layer; and a first outer skin portion made of a
foil, the continuous one-piece carrier layer forming in a region of
a subsequently mounted, second outer skin portion an exposed,
large-area supporting surface for the second outer skin
portion.
14. The intermediate product according to claim 13 wherein the
large-area supporting surface is arranged with a vertical offset
relative to the first outer skin portion.
15. A method of producing a vehicle body attachment part comprising
the following steps: providing a foaming tool with a tool bottom
part having several portions; inserting a foil in the tool bottom
part, the foil resting against a first portion of the tool bottom
part; and applying a curable foaming material on the foil and a
second portion of the tool bottom part, where the foil does not
rest against the second portion to form a continuous carrier
layer.
16. The method according to claim 15 wherein the tool bottom part
comprises several tool parts.
17. The method according to claim 15 wherein at least one tool part
of the tool bottom part is movable relative to another tool part of
the tool bottom part.
18. The method according to claim 17 including providing a venting
slot between a foil edge and one of the tool parts, and venting any
gas that has developed during the foaming process through the
slot.
19. The method according to claim 16 including pressing the foil
against a second tool part with a first tool part of the tool
bottom part in order to seal off the foil with respect to one of
the first and second tool parts.
20. The method according to one of claims 15 including bonding a
second outer skin portion to the carrier layer.
Description
RELATED APPLICATIONS
[0001] The application claims priority to European Patent
Application No. 05 005 971.6 which was filed on Mar. 18, 2005.
BACKGROUND OF THE INVENTION
[0002] The invention relates to a vehicle body attachment part for
a motor vehicle, in particular a roof module, comprising a
large-area outer skin having first and second large-area outer skin
portions that are formed from different materials, and a rear
carrier layer carrying the outer skin. The first large-area outer
skin portion is formed by a foil, and the rear carrier layer is
formed by providing the foil with a foamed backing. The invention
further relates to an intermediate product and a method of
producing such a vehicle body attachment part.
[0003] Foamed vehicle body attachment parts, especially roof
modules, with a glass fiber reinforced polyurethane material are
already known. In these roof modules, glass fibers are injected in
a plastic using a long fiber injection method (LFI method). Such
preassembled roof modules are placed from above on a roof opening,
surrounded by a vehicular frame, and are fastened to the vehicular
frame
[0004] Roof modules including glass covers or, more generally,
large-area glass panels, have seals at transitions from a foamed
layer to the large-area glass panel in order to seal off connecting
points between a foil that has been produced as a separate
component, and which is provided with a foamed backing, and the
large-area glass panel. The large-area glass panel and a part that
is formed by the foil provided with the foamed backing rest against
each other with their end faces in the installed state, with the
seal being interposed therebetween. An opening, which is necessary
in a load-carrying layer for installing a glass panel, entails a
large amount of waste of expensive foil material.
[0005] Glass panels in panorama roofs are further mounted on
additional pieces, i.e., spacers, so that the glass panels have no
vertical offset with respect to adjoining parts provided with a
foamed backing.
[0006] It is the object of the invention to produce a vehicle body
attachment part for a motor vehicle, in particular a roof module,
in a simple and cost-effective manner.
SUMMARY OF THE INVENTION
[0007] The subject invention provides a vehicle body attachment
part with first and second outer skin portions and a carrier layer
that integrally extends under the second outer skin portion, which
is subsequently fastened to the carrier layer. The second outer
skin portion is directly fastened to the carrier layer, which
extends under the second outer skin portion, by bonding for
example. The position of the carrier layer is selected such that
additional spacers will not be necessary, and nevertheless a
continuous roof surface is produced that has no steps. Further, the
second outer skin portion does not protrude beyond a geometrical
envelope of the vehicle body attachment part. This results in a
high stability and a facilitated sealing off between the first and
second outer skin portions.
[0008] Each opening in the carrier layer is preferably covered by a
one-piece outer skin portion in order to increase stability. The
opening is circumscribed by a rim of the carrier layer. An outer
edge of the outer skin portion is attached to an associated rim,
preferably by a circumferentially closed attachment, e.g. by
gluing.
[0009] The first and second outer skin portions are large-area
outer skin portions, which preferably are immovably fastened. In
other words, the first and second outer skin portions are
undetachably fastened to the carrier layer.
[0010] As the foil may also extend under the outer edge of the
second outer skin portion that faces the foil, the sealing off
between the first and second outer skin portions is facilitated.
This results in a cost-effective vehicle body attachment part that
can be produced in a simple manner.
[0011] The carrier layer preferably has a large-area opening in a
region of the second outer skin portion, and extends around the
opening as a frame. As a result, the weight of the carrier layer is
reduced. In case the second outer skin portion is made of a
transparent or translucent material, for instance, a panorama roof
can be produced.
[0012] The frame may extend in one piece and in a circumferentially
closed manner around the opening. This ensures a high
stability.
[0013] Preferably, the second outer skin portion is made of glass
or clear plastic. The second outer skin portion may also be
configured as a solar panel.
[0014] Also, the second outer skin portion may be bonded to the
carrier layer. This means that the second outer skin portion is
directly and immovably fastened to the carrier layer.
[0015] Preferably a third outer skin portion is provided, which is
arranged on the carrier layer, and is constituted by a part that is
separate with respect to the first and second outer skin portions.
This allows various design options for the vehicle body attachment
part, which can be adapted according to customer preferences.
[0016] The third outer skin portion is, for instance, a foil or a
part made of a transparent or translucent material. A roof module
may thus have one or more transparent or translucent regions. As an
alternative, a solar panel can also be installed.
[0017] Preferably, a portion of the foil, which extends under the
edge of the second outer skin portion facing the foil is configured
as a water drain groove. As a result, it is not necessary to mount
an additional water drain groove, which provides a saving.
[0018] An intermediate product according to the invention comprises
a continuous, one-piece carrier layer and a first outer skin
portion made of a foil. The carrier layer forms in a region of a
subsequently mounted second outer skin portion an exposed
large-area supporting surface for the second outer skin portion.
This provides a stable overall part that can be produced as one
piece with a foaming operation.
[0019] The supporting surface is preferably arranged with a
vertical offset relative to the first outer skin portion. The first
and second outer skin portions--after fixing the second outer skin
portion on the supporting surface--thus will continue into each
other without any vertical offset; this is why the second outer
skin portion does not project beyond a geometrical envelope of the
vehicle body attachment part.
[0020] The method of producing a vehicle body attachment part
according to the invention is distinguished by the following steps:
providing a foaming tool with a tool bottom part having several
portions; inserting a foil in the tool bottom part, the foil
resting against a first portion of the tool bottom part; and
applying a curable foaming material on the foil and a second
portion of the tool bottom part, against which portion the foil
does not rest, for forming a continuous carrier layer.
[0021] The tool bottom part is preferably comprised of several tool
parts, whereby a variable positioning of individual tool parts is
made possible.
[0022] It is preferred that at least one tool part of the tool
bottom part be movable relative to another tool part of the tool
bottom part.
[0023] A venting slot may be provided between a foil edge and one
of the tool parts. Any gases developed during the foaming process
may escape through the venting slot. The venting slot results in a
good surface quality.
[0024] The foil is pressed against a second tool part by a first
tool part of the tool bottom part in order to largely seal off the
foil with respect to one of the tool parts. As the foil is sealed
off, a partial seal on the tool side can be omitted.
[0025] It is preferred that the second outer skin portion be bonded
to the carrier layer. Thus, it is simple to produce a panorama roof
or a roof module having a roof opening.
[0026] These and other features of the present invention can be
best understood from the following specification and drawings, the
following of which is a brief description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIG. 1 is a perspective view of a motor vehicle comprising a
vehicle body attachment part, according to the invention, in the
form of a panorama roof.
[0028] FIG. 2 is a view of an intermediate product, according to
the invention, for producing the vehicle body attachment part
according to FIG. 1.
[0029] FIG. 3 is a sectional view along line III-III in FIG. 2 of
the intermediate product with outer skin portions being fixed.
[0030] FIG. 4 is an enlarged sectional view of the intermediate
product in a foaming tool, with a tool upper part of the foaming
tool being in a slightly lifted position.
[0031] FIG. 5 shows an enlarged detail of the region designated
with X in FIG. 4 with the foaming tool in a first embodiment.
[0032] FIG. 6 shows an enlarged detail according to FIG. 5 of the
foaming tool in a second embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0033] In FIG. 1 there is shown a vehicle body attachment part in
the form of a roof module 10. The vehicle body attachment part
could also be configured, however, as a fender, door or lid (engine
hood, trunk lid) of a vehicle.
[0034] The roof module 10 has a large-area outer skin 12 that has
several outer skin portions including first, second, and third
outer skin portions 14, 16, 18. The first, second, and third outer
skin portions 14, 16, 18 are plate-shaped, large-area portions that
are formed from different materials.
[0035] The first outer skin portion 14, in an installed state
adjoining a windscreen, is of a deep-drawn foil 20 that is made of
plastic or aluminum, and is preferably dyed throughout (FIG. 3).
The foil 20, which forms an outer skin of the first outer skin
portion 14, extends under an edge 22 of the adjoining second outer
skin portion 16 (FIG. 3) that faces the foil 20. The foil 20 is
also shaped as a water drain groove 24.
[0036] The second outer skin portion 16, arranged to adjoin the
first outer skin portion 14, is made of a transparent material such
as glass, or is made of a translucent material.
[0037] The third outer skin portion 18 is likewise configured as a
separate part with respect to the first and second outer skin
portions 14, 16, and is shown in FIG. 3 as a glass panel. Thus, a
stable panorama roof is produced that has large glass faces, and
which is fastened to a roof frame as a completed roof module. The
third outer skin portion 18--just like the first outer skin portion
14--could also be made of the foil 20 or a solar panel (not
shown).
[0038] Adjacent to a rear side of the foil 20 is a carrier layer 26
that is produced by providing the foil 20 with a foamed backing
using a LFI method. The carrier layer 26 integrally extends under
the second and third outer skin portions 16, 18 and has, in a
region of the second and third outer skin portions 16, 18, one
large-area opening 28, 29 in each of the second and third outer
skin portions 16, 18, respectively. The carrier layer 26 extends
around each respective opening 28, 29 in a circumferentially closed
manner as a one-piece frame 30 (FIG. 2). The carrier layer 26
defines a supporting surface 32 for the second and third outer skin
portions 16, 18, which is exposed towards a top and has a large
surface area. The second outer skin portion 16 and the third outer
skin portion 18 cover their corresponding large-area openings 28
and 29, respectively. An outer edge of the second or the third
outer skin portion 16, 18 lies on a rim of the carrier layer 26
surrounding the respective large-area opening 28 or 29.
Particularly, the outer edges of the second and third outer skin
portion 16, 18 are attached to the respective rim continuously
along the entire edge. The second outer skin portion 16 completely
covers only the first opening 28, and the third outer skin portion
18 completely covers only the second opening 29.
[0039] The supporting surface 32 for the second and third outer
skin portions 16, 18 is configured such that after applying the
outer skin portions 16, 18, the latter will not project beyond a
geometrical envelope of the first outer skin portion 14. This
provides a stepless, visually appealing surface for the roof module
10. As an alternative, it would also be possible to integrally form
projections (spacers) on the carrier layer 26, where an upper side
of these projections forms the supporting surface. The second and
third outer skin portions 16, 18 are not bonded to the projections,
rather the second and third outer skin portions 16, 18 rest against
the projections, so that the projections are responsible for the
exact vertical alignment.
[0040] The second and third outer skin portions 16, 18 are
subsequently and directly fastened to the supporting surface 32 of
the carrier layer 26, by bonding, for example. An adhesive bead is
identified by reference numeral 33. This means that the second and
third outer skin portions 16, 18 are immovably fastened to the
carrier layer 26, i.e., the second and third outer skin portions
16, 18 cannot be detached from each other. As such, the second
outer skin portion 16 has a front edge 22 attached to the foil 20,
which is attached to the carrier layer 26.
[0041] FIG. 4 shows a foaming tool in a slightly lifted position
with a foamed carrier layer 26. It is with the aid of such a
foaming tool that vehicle body attachment parts, such as the
initially mentioned panorama roof module 10, fenders, doors or lids
(engine hood, trunk lid) of the vehicle, are produced.
[0042] The foaming tool includes a tool upper part 34 and a tool
bottom part 36, with the tool bottom part 36 having several
portions including a first portion 38 and a second portion 40. The
foil 20 rests against the first portion 38, but not against the
second portion 40.
[0043] The tool bottom part 36 has several tool parts 42, 44, 46,
with the tool parts 42 and 46 being movable in vertical and
horizontal direction (FIGS. 4 and 5) as well as in an oblique
direction (FIG. 6) relative to the tool part 44.
[0044] The tool parts 42, 44 have faces 43, 45 facing each other,
between which the foil 20 extends. The faces 43, 45 are each
inclined relative to a vertical line by an angle .alpha. (FIG. 5).
At an upper corner portion of the tool part 44, there is formed a
protruding sealing nose 47 that provides sealing between tool part
44 and foil 20.
[0045] In the method of producing a foamed vehicle body attachment
part, the deep-drawn foil 20 is inserted in the first portion 38 of
the tool bottom part 36 with the tool part 42 being lowered. The
foil 20 runs towards a lateral recess 48 in the tool part 42 and
extends with a distal edge into the lateral recess 48 in order to
compensate for any tolerances during the deep-drawing of the foil
20, in particular in an end region thereof.
[0046] When the tool part 42 is moved upwards, the foil 20 is
clamped between the faces 43, 45, especially in the region of the
sealing nose 47, so that no foam material will enter the space
between the faces 43, 45 and a sealing on the tool may be
eliminated.
[0047] Finally, the tool part 46 is moved horizontally to the right
to a stopper on the tool part 42.
[0048] After the deep-drawn foil 20 is clamped, a liquid
polyurethane material is applied on a backside of the foil 20 and
on the second portion 40 of the tool bottom part 36, with glass
fibers being injected in the process by using the LFI method.
[0049] The tool upper part 34 and the tool bottom part 36 are
brought together. The polyurethane material reacts to foam and
fills a cavity defined between the tool upper and bottom parts 34,
36; such cavity defining the shape of the continuous carrier layer
26 after foaming. After the foaming process, the tool part 46 is
moved to the left and the tool part 42 is moved downwards, so that
the produced intermediate product can be removed from the tool.
[0050] To a side of the water drain groove 24 the foil 20 is
trimmed, so that the trimmed edge does not project with respect to
the adjoining carrier layer 26.
[0051] After having produced the intermediate product (FIG. 2), the
second and third outer skin portions 16, 18 are bonded to the
carrier layer 26
[0052] FIG. 6 shows a further embodiment of the tool for producing
the panorama roof module 10, which is similar to the embodiment
that is described above, and to which reference is made.
[0053] In this embodiment, the tool part 42 of the tool bottom part
36 can be moved relative to the tool part 44 in oblique direction,
so that the tool part 42 presses the foil 20 with an inclined face
43 against an inclined face 45 and no foam material can enter a
space between the faces 43, 45. This eliminates a need for sealing
on the tool side. The faces 43, 45 have the same inclination and
are arranged in a region of a lower edge of the tool part 44.
[0054] The tool part 44 has a vertical venting slot 50 that allows
gases developed during the foaming process to escape. A gap B of
the venting slot 50 decreases with an increasing distance to the
carrier layer 26, and extends approximately to a lower third of the
tool part 44. The gap width B is so small that no foam will enter
the gap, i.e. the size of the gap B shown in FIG. 6 is
overexaggerated for clarity purposes.
[0055] The foaming method and the process of bonding the second and
third outer skin portions 16, 18 is similar to the first
embodiment, and reference is made to this.
[0056] The first embodiment according to FIG. 5 could also be
provided with a venting slot 50.
[0057] Although a preferred embodiment of this invention has been
disclosed, a worker of ordinary skill in this art would recognize
that certain modifications would come within the scope of this
invention. For that reason, the following claims should be studied
to determine the true scope and content of this invention.
* * * * *